Concave and convex-patterned multi-colored fiber pile fabric

ABSTRACT

The multi-colored fiber pile fabric of the present invention has at least one cut pile layer comprising a plurality of cut piles extending from at least one surface side of a knit or weave structure formed from organic fiber yarns, the cut pile layer comprises non-crimped pile fibers  5  formed from non-crimped organic fibers, crimped pile fibers  6  formed from crimped organic fibers and having a pile height lower than that of the non-crimped pile fibers  5  and crimped or non-crimped pile fibers  7  formed from crimped or non-crimped organic fibers and having a pile height lower than that of the crimped pile fibers  6 , at least one type of pile fibers of the piles fibers  5, 6  and  7  having a color different in lightness or hue or lightness and hue from the other(s),

TECHNICAL FIELD

The present invention relates to a multi-colored pile fabric and aconcave-and convex-patterned multicolored pile fabric. Moreparticularly, the present invention relates to a multi-colored pilefabric having a cut pile layer formed from three, types of pile fibersdifferent in pile height from each other, of which three types of pilefibers at least one type of pile fibers have a color different inlightness and-or hue from the others, and a concave-and convex-patternedmulti-colored pile fabric in which a concave-and convex-pattern isformed in the above-mentioned cut pile layer of the multi-colored pilefabric.

BACKGROUND ART

Currently, a large amount of pile fabric is employed for car seats, etc.Particularly, recently, car seats are required to have improvedproperties and performances, and sometimes to be provided withmulti-colored patterns and concave-and convex-patterns, in addition tothe conventionally demanded properties and performances.

Japanese Unexamined Patent Publication No. 63-145457 discloses amulti-color patterned pile fabric in which the piles are formed fromthree different types of man-made fibers (filaments) consisting of highshrinkage fibers, moderate shrinkage fibers and low shrinkage fibers. Inthis type of pile fabric, though a natural fiber-like hand and color canbe realized, concave-and convex-patterns cannot be sufficientlyrealized.

Japanese Unexamined Patent Publication No. 6-49731 discloses a pilefabric containing, as pile yarns, mixed filament yarns comprising two ormore types of filaments different in dyeing property or color from eachother. In this type of pile fabric, a grandrelle pattern can be formed.However, even in this type of pile fabric, a concave-and convex-patternhas not yet been realized. Further, Japanese Unexamined PatentPublication No. 2001-271255 discloses a pile fabric in which pile yarnsproduced from crimped filaments comprising a cationic dye-dyeablepolyester and non-crimped polyester filaments are used. In this type ofpile fabric, a formation of a concave-and convex-pattern has not yetbeen realized.

As mentioned above, in the conventional multi-colored pile fabrics,various devices for realizing multi-colored patterns have been made.However, the addition of the concave-and convex-patterns to themulti-colored patterns has not yet satisfactorily realized. Also,further development is desired to the multi-colored patterns on pilefabrics.

DISCLOSURE OF THE INVENTION

An object of the present invention is to provide a pile fabric havingample multi-colored patterns and capable of forming concave-andconvex-patterns thereon, and a pile fabric having both the multi-coloredpatterns and the concave-and convex-patterns.

The multi-colored fiber pile fabric of the present invention comprises aground structure portion having a knit or weave structure formed fromorganic fiber yarns and at least one cut pile layer comprising aplurality of cut piles, combined with the ground structure portion by aknitting or weaving procedure of the organic fiber yarns, and extendingoutward from at least one surface side of the ground structure portion,

wherein

-   -   the cut pile layer comprises (1) non-crimped pile fibers        comprising non-crimped organic fibers, (2) crimped pile fibers        comprising crimped organic fibers and having a pile height lower        than that of the non-crimped pile fibers (1), and (3) crimped or        non-crimped pile fibers comprising crimped or non-crimped        organic fibers and having a pile height lower than that of the        crimped pile fibers (2), and    -   at least one type of pile fibers of the pile fibers (1), (2) and        (3) having a color different in lightness or hue or in lightness        and hue from the other or others.

In an embodiment of the multi-colored pile fabric of the presentinvention, the cut pile layer comprises mixed fiber cut piles, in eachof which piles, three types of the pile fibers of the non-crimped pilefibers (1), the crimped pile fibers (2) and crimped or non-crimped pilefibers (3) are mixed altogether.

In another embodiment of the multi-colored pile fabric of the presentinvention, the cut pile layer comprises mixed fiber cut piles, in eachof which piles, at least two types of pile fibers of the non-crimpedpile fibers (1), the crimped pile fibers (2) and the crimped ornon-crimped pile fibers (3) are mixed with each other.

In still another embodiment of the multi-colored pile fabric of thepresent invention, the cut pile layer comprises a plurality ofnon-crimped cut piles consisting of only the non-crimped pile fibers(1), a plurality of crimped cut piles consisting of only the crimpedpile fibers (2) and a plurality of crimped or non-crimped cut pilesconsisting of only the crimped or non-crimped pile fibers (3).

In the multi-colored pile fabric of the present invention, thenon-crimped pile fibers (1) are preferably selected from the groupconsisting of non-crimped polyethylene terephthalate fibers, non-crimpedpolybutylene terephthalate fibers, non-crimped polytetramethyleneterephthalate fibers, and non-crimped polytrimethylene terephthalatefibers.

In the multi-colored-pile fabric of the present invention, the crimpedpile fibers (2) are preferably selected from cationic dye-dyeablecrimped polyester fibers.

In the multi-colored pile fabric of the present invention, the crimpedor non-crimped pile fibers (3) preferably comprise a polyestercopolymer, the principal monomers for the copolymer preferably beingethylene glycol and terephthalic acid, the comonomer copolymerized withthe principal monomers preferably being at least one member selectedfrom isophthalic acid, naphthalene dicarboxylic acid, adipic acid, andsebacic acid, diethyleneglycol, polyethyleneglycols, bis-phenol andbis-phenol sulfon.

In the multi-colored pile fabric of the present invention, one type ofpile fiber of the non-crimped pile fibers (1) and the crimped ornon-crimped pile fibers (3) are preferably colored with a pigment mixedinto a polymer component from which the pile fibers are formed.

The concave-and convex-patterned multi-colored fiber pile fabric (1) ofthe present invention is produced from the multi-colored fiber pilefabric of the present invention as mentioned above, wherein in at leastone partial region of the cut pile layers top portions of thenon-crimped pile fibers (1) are removed by a chemical etching procedureto such an extent that the remaining non-crimped pile fibers (1-a) havea pile height controlled within the range of lower than that of theoriginal non-crimped pile fibers (1) but not lower than that of thecrimped pile fibers (2), to thereby increase the degree of exposure ofthe top portions of the crimped pile fibers (2) located in the partialregion.

The concave-and convex-patterned multi-colored fiber pile fabric (2) isproduced from the multi-colored fiber pile fabric of the presentinvention as mentioned above, wherein in at least one partial region ofthe cut pile layer, top portions of the non-crimped pile fibers (1) andthe crimped pile fibers (2) are removed by a chemical etching procedureto such an extent that the remaining non-crimped pile fibers (1-a) andthe remaining crimped pile fibers (2-a) have pile heights controlledwithin the range of lower than that of the original crimped pile fibers(2) but not lower than that of the crimped or non-crimped pile fibers(3), to thereby increase the degree of exposure of the top portions ofthe remaining crimped pile fibers (2-a) or the crimped and non-crimpedpile fibers (3) located in the partial region.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an explanatory cross-sectional view of an embodiment of themulti-colored fiber pile fabric of the present invention,

FIG. 2 shows an explanatory cross-sectional view of another embodimentof the multi-colored fiber pile fabric of the present invention,

FIG. 3 shows an explanatory cross-sectional view of an embodiment of theconcave-and convex-patterned multi-colored fiber pile fabric of thepresent invention,

FIG. 4 shows an explanatory cross-sectional view of another embodimentof the concave-and convex-patterned multi-colored fiber pile fabric ofthe present invention,

FIG. 5 shows an explanatory cross-sectional view of still anotherembodiment of the concave-and convex-patterned multi-colored fiber pilefabric of the present invention,

FIG. 6 shows an explanatory cross-sectional view of further embodimentof the concave-and convex-patterned multi-colored fiber pile fabric ofthe present invention,

FIG. 7 shows an explanatory cross-sectional view of still furtherembodiment of the concave-and convex-patterned multi-colored fiber pilefabric of the present invention, and

FIG. 8 shows a knitting structure of an embodiment of a multi-coloredfiber pile knitted fabric of the present invention.

BEST MODE OF CARRYING OUT THE INVENTION

The multi-colored fiber pile fabric comprises (A) a ground structureportion having a knit or weave structure formed from organic fiber yarnsand (B) at least one cut pile layer. The cut pile layer is composed of aplurality of cut piles and combined with the ground structure portion bya knitting or weaving procedure of the organic fiber yarns. The cutpiles extend outward from at least one surface side of the groundstructure portion.

The cut pile layer of the multi-colored fiber pile fabric of the presentinvention comprises

(1) non-crimped pile fibers comprising non-crimped organic fibers,

(2) crimped pile fibers comprising crimped organic fibers and having apile height lower than that of the non-crimped pile fibers (1); and

(3) crimped or non-crimped pile fibers comprising crimped or non-crimpedorganic fibers and having a pile height lower than that of the crimpedpile fibers (2), and at least one type of pile fibers (1), (2) and (3)having a color different in lightness or hue or in lightness and huefrom the remaining type or types of the pile fibers.

In an embodiment of the multi-colored fiber pile fabric of the presentinvention, the cut pile layer comprises a plurality of cut piles eachformed from mixed pile fibers comprising the above-mentioned non-crimpedpile fibers (1), crimped pile fibers (2) and crimped or non-crimped pilefibers (3), namely three types of fiber-mixed cut piles.

In the multi-colored fiber pile fabric having a cross-sectionalstructure as shown in FIG. 1, a plurality of cut piles 4A formed from aplurality of pile-forming yarns. (not shown in FIG. 1) are incorporated,by a weaving procedure, into a ground structure portion 3 constitutedfrom a plurality of warps 1 and a plurality of wefts 2 and having aweave structure, to thereby provide a cut pile layer 4 from the cutpiles 4A. Each of the cut piles 4A is constituted from a plurality ofnon-crimped pile fibers 5, a plurality of crimped pile fibers 6 and aplurality of crimped or non-crimped pile fibers 7. The non-crimped pilefibers 5 have a highest pile height 5H (a distance between a meansurface of the ground structure portion and a top end of the pilefiber), the crimped pile fibers 6 have a pile height 6H lower than thepile height 5H, and the crimped or non-crimped pile fibers 7 has a pileheight 7H lower than the pile height 6H.

In the pile fabric having the cross-sectional structure shown in FIG. 1,the crimped pile fibers 6 having a middle pile height cause theresultant cut fiber piles to exhibit an increased bulkiness and anenhanced resistance to flatting (being laid flat).

When the cut pile layer is observed from above, though the top portionsof the non-crimped pile fibers 5 having a highest pile height 5H arewell observed, the crimped pile fibers 6 having a middle pile height 6Hare partially shielded by the top portions of the non-crimped pilefibers 5 and thus only the non-shield portions of the crimped pilefibers can be observed. Also, the crimped or non-crimped pile fibers 7having a lowest pile height 7H are mostly covered by the non-crimpedpile fibers 5 and the crimped pile fibers 6 and only some portions ofthe pile fibers 7 can be observed. Namely, in the case where, the pilefibers (1), (2) and (3) are different in lightness and/or hue from eachother, in the appearance of the cut pile layer of FIG. 1 from above, thecrimped pile fibers (2) are observed in a sprinkly colored patternthrough the non-crimped pile fibers (1), and the crimped or non-crimpedpile fibers (3) are also observed in a sprinkly colored pattern to anincreased degree compared to that of the crimped pile fibers (2) throughthe pile fibers (1) and (2), and as a whole, a multi-colored pattern isprovided. The amount of each of the pile fibers (1), (2) and (3)observable from above is variable in response to the pile heights, andpresence or absence of crimps of the fibers, and thus variousmulti-colored patterns can be formed.

The mixed fiber mass ratios or mixed fiber number ratios of the pilefibers (1), (2) and (3) contained in each of the piles 4A can beappropriately established in dependence on the pattern, color and handof the target pile fabric.

In another embodiment of the multi-colored fiber pile fabric of thepresent invention, the cut pile layer comprises two or more types ofmixed fiber piles comprising at least two different types of mixed pilefibers of the above-mentioned non-crimped pile fibers (1), crimped pilefibers (2) and crimped or non-crimped pile fibers (3).

A cross section of the above-mentioned another embodiment of themulti-colored fiber pile fabric is shown in FIG. 2. Referring to FIG. 2,a cut pile layer 4 is constituted from three different types of fiberpiles 4B, 4C and 4D, each comprising a mixture of two different types ofpile fibers. The mixed two type fiber piles 4B are constituted from twodifferent types of fibers, namely the non-crimped pile fibers 5 andcrimped pile fibers 6, the mixed two type fiber piles 4C are constitutedfrom two different pile fibers, namely the crimped pile fibers 6 andcrimped or non-crimped pile fibers 7, and the mixed two type fiber piles4D are constituted from two different pile fibers, namely thenon-crimped pile fibers 5 and the crimped or non-crimped pile fibers 7.In the pile fabric shown in FIG. 2, where at least one type of pilefibers selected from the pile fibers (1), (2) and (3) are different inhue and/or lightness from the others, the mixed colors of the cut piles4B, 4C and 4D are different from each other, and the appearance color ofthe cut pile layer observed from above varies in dependence on thecombinations of the two types of pile fibers contained in each of thecut piles. Accordingly, the cut pile layer shown in FIG. 2 exhibitscomplicated multi-colored patterns in response to the differences inpile height and color between the cut piles.

FIG. 3 shows a cross-sectional profile of another example of theabove-mentioned embodiment of the multi-colored fiber pile fabric.Referring to FIG. 3, a cut pile layer 4 is constituted from two types ofmixed two type fiber pile 4B and 4C. The mixed two type fiber pile 4B isformed from non-crimped pile fibers 5 and crimped pile fibers 6, theother mixed two type fiber pile 4C is formed from the crimped pilefibers 6 and the crimped or non-crimped pile fiber 7. The combinationsof the two types of mixed two type fiber piles include, in addition tothe combination 4B+4C, a combination of mixed two type fiber piles 4B+4D(non-crimped pile fibers 5+crimped or non-crimped pile fibers 7) and acombination of piles 4C+4D.

In the embodiments of the pile fabric of the present invention shown inFIGS. 2 and 3, the combinations, mixing fiber mass ratio and mixingfiber number ratio of the two types of pile fibers from which each ofthe cut piles 4B, 4C and 4D is constituted, and the arrangement, pilenumber ratio, and pile mass ratio of the mixed two type fiber piles 4B,4C and 4D can be appropriately established in response to the structure,color and pattern of the target pile fabric.

Namely, in each of the combinations of the above-mentioned mixed twotype fiber piles, the appearance and patterns of the cut pile layerobserved from above can be widely varied by varying the pile height,crimping degree, hue and lightness of the pile fibers from which thepiles are formed.

In still another embodiment of the multi-colored pile fabric of thepresent invention, the cut pile layer comprises a plurality ofnon-crimped cut piles consisting of only the non-crimped pile fibers (1)(and having a heighest pile height), a plurality of crimped cut pilesconsisting of only the crimped pile fibers (and having a middle pileheight), and a plurality of crimped or non-crimped cut piles consistingof only the crimped or non-crimped pile fibers (3) (and having a lowestpile height).

In the explanatory cross-sectional profile of the still anotherembodiment of the multi-colored fiber pile fabric, as shown in FIG. 4,cut piles 4E consist of only non-crimped pile fibers 5, cut piles 4Fconsist of only crimped pile fibers 6 and cut piles 4G consist of onlycrimped or non-crimped pile fibers 7. In this type of cut pile layerformed from the cut piles different in pile height from each other, whenobserved from above, all of the cut piles 4E, 4F and 4G can be seen, oronly the cut piles 4E and 4F can be seen, or only the cut piles 4E canbe seen, by changing the observation angle and/or direction with respectto the cut pile fabric surface, and thus complicated multi-coloredpatterns are formed due to differences in pile height and hue of thefiber piles. The arrangement, mass ratio and cut pile number of the cutpiles 4E, 4F and 4G can be appropriately established in response to thedesired pattern of the cut pile fabric.

In the multi-colored fiber pile fabric of the present invention, thenon-crimped pile fibers (1), the crimped pile fibers (2) and crimped ornon-crimped pile fibers (3) are respectively and independently from eachother selected from organic fibers, namely, organic natural fibers,organic synthetic fibers, organic semi-synthetic fibers and organicregenerated fibers. The organic natural fibers include cotton, wool andhemp fibers, etc. The organic regenerated fibers include viscose rayonfibers, the organic synthetic fibers include-polyester, nylon, andpolyolefin fibers, etc, and the organic semi-synthetic fibers includecellulose acetate fibers, etc.

The non-crimped pile fibers (1) contained in the pile fabric of thepresent invention have a highest pile height and thus form a highestlevel of the cut pile layer, and thus are preferably formed fromnon-crimped polyester fibers having a high Young's modulus and a highresistance to flatting (being laid flat). When the pile fibers (1) arecrimped fibers, the shielding effect of the resultant pile fibers on thecrimped pile fibers (2) and the crimped or non-crimped pile fibers (2)increases, and thus the multi-coloring effect of the multi-coloredpattern of the resultant cut pile fabric decreases.

The polyester fibers for the non-crimped pile fibers (1) are preferablyselected from non-crimped polyethylene terephthalate fibers, non-crimpedpolybutylene terephthalate fibers, non-crimped polytetramethyleneterephthalate fibers, and non-crimped polytrimethylene terephthalatefibers.

The crimped pile fibers (2) having a middle pile height are used toenhance the bulkiness and elastic modulus of compression of the cutpiles or the cut pile layer, and the high bulkiness of the crimped pilefibers (2) causes the shielding effect of the non-crimped pile fibers(1) having a highest pile height to decrease and enables the degree ofexposure of the crimped pile fibers (2) to the external appearance ofthe cut pile layer to enhance. The crimped pile fibers are not limitedto specific types of fibers, as long as the fibers (2) have a necessaryand sufficient degree of crimping. Preferably, the crimped pile fibers(2) are selected from crimped polyester filaments, crimped and modifiedpolyester filaments dyeable with cationic dyes, and crimped nylonfilaments, particularly cationic dye-dyeable crimped polyesterfilaments.

The above-mentioned crimped pile fibers (2) can be produced by applyingan appropriate crimping procedure to the non-crimped fibers from whichthe target crimped fibers are formed. For example, for thermoplasticorganic fibers, a false-twisting procedure, an air jet crimpingprocedure or a compressive crimping procedure can be applied.

The crimped or non-crimped pile fibers (3) having a lowest pile heightmay be crimped or non-crimped. The fibers for the-pile fibers (3) arepreferably selected from organic fibers, more preferably from thoseuseful for the non-crimped organic fibers, particularly polyesterfibers.

The polyester resins for producing the polyester fibers appropriate toeach of the pile fibers (1), (2) and (3) are produced from adicarboxylic acid component and a diglycol component. Preferably,terephthalic acid is mostly employed for the dicarboxylic acid. Also,for the diglycol component, preferably at least one alkylene glycolselected from ethylene glycol, trimethylene glycol and tetramethyleneglycol is mostly employed. Also, the polyester resins optionally containthird components in addition to the above-mentioned dicarboxylic acidand glycol components. As the third components, at least one memberselected from cationic dye-dyeable anionic components, for example,sodium sulfoisophalate; other dicarboxylic acids than terephthalic acid,for example, isophthalic acid, naphthalene dicarboxylic acids, adipicacid and sebacic acid; other glycol compounds than alkylene glycols, forexample, diethylene glycol, polyethylene glycol, bisphenol A andbis-phenolsulfone, may be employed.

Where the organic fibers for forming the pile fibers (1), (2) and/or (3)are man-made fibers, the polymeric material, from which the man-madefibers are produced, optionally contain at least one member selectedfrom delustering agents (titanium dioxide), fine pore-forming agent(metal salts of organic sulfonic acids), coloring-preventive agents,thermal stabilizers, flame retardants (diantimony trioxide), fluorescentbrightening agents, coloring pigments, anti-statics (metal salts ofsulfonic acids), moisture-absorbing agents (polyoxyalkyleneglycol),anti-bacterial agents, inorganic particles, etc. Particularly, thecoloring agents can impart a desired hue or lightness to the pile fibers(1), (2) and/or (3). Also, the delustering agents are effective tocontrol the lightness of the pile fibers (1), (2) and/or (3).

In the multi-colored fiber pile fabric of the present intention, atleast one type of fibers of the non-crimped pile fibers (l), the crimpedpile fibers (2) and/or the crimped or non-crimped pile fibers (3) fromwhich the cut pile layer is formed, must be different in lightness orhue or lightness and hue from other or others. The hue mentioned aboveinclude white, black and glay colors. The differences in lightness andhue between the pile fibers (1), (2) and (3) may be in an extent suchthat the differences are perceptible with the naked eye exhibiting anormal visual sensation, and the difference in the lightness ispreferably 5 or more in terms of psychrometric lightness in the Munsellcolor system.

In the multi-colored fiber pile fabric of the present invention, thepile fibers (1), (2) and (3) may be the same in hue as each other and atleast one type of pile fibers of the pile fibers (1), (2) and (3) may bedifferent in lightness from others, or the pile fibers (1) (2) and (3)may be the same in lightness as each other and at least one type of pilefibers of the pile fibers (1), (2) and (3) are different only in the huefrom others; or at least one type of pile fibers of the pile fibers (1),(2) and (3) are different in both the hue and the lightness from others.

To impart, to at least one type of pile fabric of the pile fibers (1),(2) and (3), a color different in lightness and/or hue from others, eachgroup of the fibers of the pile fibers (1), (2) and (3) should becolored in a desired hue and lightness. For example, one or two types ofthe fibers of the pile fibers (1), (2) and (3) may be formed from acationic dye-dyeable polyester resin and dyed in a color the same asothers or different from others, in hue and/or lightness, and theremaining types of the fibers may be formed from a cationicdye-undyeable polyester resin colored or non-colored with a coloringpigment.

The cationic dye-dyeable polyester resins usable for the presentinvention may be selected from conventional cationic dye-dyeablepolyester resins. For example, a cationic dye-dyeable polyester resinproduced by using a dicarboxylic acid component containing, in additionto, for example, terephthalic acid, sodium sulfoisophthalate in anamount of 1.0 to 5.0 molar % based on the total molar amount of thedicarboxylic acid component, may be employed.

To impart, to at least one type of fibers of the pile fibers (1), (2)and (3), a lightness different from others, the type of pile fibers areformed from a copolymerized polyester resin produced by copolymerizingthe above-mentioned usual (ordinary) dicarboxylic acid component andalkylene glycol component with a third copolymerization componentcomprising at least one compound selected from the other dicarboxylicacids than the usual (ordinary) dicarboxylic acid component, forexample, naphthalene dicarboxylic acids, adipic acid and sebacic acid;and other glycol compounds than the usual alkylene glycol component, forexample, diethylene glycol, polyethylene glycols, bis-phenol-A andbis-phenolsulfone; and the remaining type of pile fibers are formed fromordinary (regular) type of polyester resin.

By forming the pile fibers (1), (2) and (3) in the above-mentioned way,when the pile fibers (1), (2) and (3) are dyed altogether to the samehue as each other in a single disperse dye-dyeing both, the pile fibersmade from the copolymerized polyester resin can be dyed in a highercolor density (lower lightness) than that of the pile fibers made fromthe ordinary (regular) polyester resin.

In the multi-colored fiber pile fabric of the present invention, thenon-crimped pile fibers (1), the crimped pile fibers (2) and the crimpedor non-crimped pile fibers (3) are colored so that at least one type ofthe pile fibers of the above-mentioned pile fibers (1) to (3) have acolor different in hue and/or lightness from the others. To impart, toeach of the pile fibers (1), (2) and (3) a color different in hue and/orlightness from the others, for examples the non-crimped pile fibers (1)are formed from an ordinary (regular) polyester resin not modified andundyeable with the cationic dyes; the crimped pile fibers (2) are formedfrom a cationic dye-dyeable polyester copolymer resin; the crimped ornon-crimped pile fibers are formed from a cationic dye-undyeablepolyester copolymer resin (easy dyeable with disperse dyes); and thepile fibers (1), (2) and (3) are dyed altogether in a single dyeing bothcontaining a cationic dye and a disperse dye in this case, thenon-crimped pile fibers (1) and the crimped or non-crimped pile fibers(3) are dyed with the disperse dye into the same hue as each other, andthe crimped pile fibers (2) are dyed with the cationic dye into a colorthe same or different in hue and/or lightness as or from the pile fibers(1) and (3). Also, in this case, the crimped or non-crimped pile fibers(3) are dyed with a higher color density (namely a lower lightness) thanthat of the non-crimped pile fibers (1). There are no limitations to theindividual fiber thickness and the total thickness (yarn count) of thepile-forming yarn formed from the pile fibers (1), (2) and/or (3).Preferably, the individual fiber thickness of each of the pile fibers(1), (2) and (3) is in the range of from 0.1 to 10 dtex, and the totalthickness of the above-mentioned pile-forming yarn is in the range offrom 30 to 300 dtex. If the individual fiber thickness of each type ofthe pile fibers is less than 0.1 dtex, the resultant piles may exhibitan insufficient resistance to being laid flat, and the resultant pilelayer may exhibit too low a soft hand. If the individual fiber thicknessis more than 10 dtex, the resultant pile layer may exhibit too high astiff hand. Also, if the total thickness of the pile-forming yarn isless than 30 dtex, the resultant pile layer may not provide asatisfactory multi-colored pattern. Also, the total yarn thickness ismore than 300 dtex, the resultant pile-forming yarns may exhibit aninsufficient handling property in yarn-processing procedures andknitting or weaving procedures. There is no limitation to thecross-sectional profiles of the individual fibers for the pile fibers(1), (2) and (3). Usually, the individual fibers in the pile fibers (1),(2) and (3) have a regular, namely circular or irregular, for example,triangular, flat, cross-formed, hexa-lobated or hollow cross-sectionalprofile.

There is no limitation to the knitting and weaving structures of themulti-colored fiber pile fabric of the present invention. The pilefabric of the present invention includes cut pile fabrics produced bycutting the loop piles of loop pile fabrics, for example, warp pileweaves, weft pile weaves, sinker pile knits, raschel pile knits andtricot pile knits.

In the multi-colored fiber pile fabric of the present invention, thereis no specific limitation to the type of the yarns, the type of thefibers, the individual fiber thickness and the total yarn thickness ofthe ground structure portion. The ground structure portion can be formedfrom the yarns usable for the conventional pile fabric. Generally, theyarns for the ground structure portion of the pile fabric of the presentinvention are preferably selected from polyester multifilament yarns.The polyester multifilament yarns enable the resultant ground structureportion to exhibit a pleasant hand and a high dyeability.

The cut pile layer of the multi-colored fiber pile fabric of the presentinvention preferably has a contribution density of the pile fibers inthe range of from 34,000 to 220,000 dtex/cm². If the pile fibercontribution density is less than 34,000 dtex/cm², the resultant cutpile layer may exhibit an insufficient resistance to flatting (beinglaid flat), of the pile fibers, especially in the case where the pilefabric is used as a cart sheet which is used under severe use conditionsand thus in which the pile fibers may be significantly laid flat. Also,if the pile fiber contribution density is more than 220,000 dtex/cm²,the resultant cut pile layer may exhibit too stiff a hand and may causethe production cost of the pile fabric to be too high.

The multi-colored fiber pile fabric of the present invention can beproduced by, for example, the following procedures.

As fibers for forming the non-crimped pile fibers (1), non-crimpedorganic fibers, for example, non-crimped polyester filaments, having ashrinkage in boiling water (BWS) of 4% or less are preferably used.

If the shrinkage in boiling water (BWS) of the fibers for thenon-crimped pile fibers (1) is more than 4%, and when the resultant pilefabric is subjected to a heat treatment, the heat treated pile fabricmay exhibit too high a heat shrinkage, of the pile fibers, the resultantpile layer may exhibit an insufficient pile height of the non-crimpedpile fibers in the pile layer and thus the multi-color pattern formed inthe pile layer may be unsatisfactory. Also, when a etching treatment,which will be explained hereinafter, is locally applied to the cut pilelayer, the resultant concave-and convex-pattern in the pile layer may beunsatisfactory.

In order to produce the organic fibers having a shrinkage in boilingwater of 4% or less, an appropriate treatment for preventing the heatshrinking is applied to the non-crimped organic fibers. For example,polyester filaments are employed, preferably a dry heat treatment isapplied at a temperature of 180 to 220° C. to a polyester filament yarnproduced by usual filament-forming and drawing procedures.

The crimped pile fibers (2) usable for the multi-colored fiber pilefabric of the present invention are preferably selected from crimpedorganic fibers, for example, crimped polyester multifilaments, having apercentage crimp of preferably 8% or more, more preferably 10 to 30%. Ifthe percentage crimp of the crimped organic fibers for forming thecrimped pile fibers is less than 8%, and a cut pile layer is formed fromthe crimped organic fibers, particularly, the resultant cut pile layeris heat-treated, the crimped pile fibers in the cut pile layer may notexhibit sufficient bulkiness and resistance to compression. Also, inthis case, the resultant pile fibers in the cut pile layer may have apile height not sufficiently lower than that of the non-crimped pilefibers. If the percent crimp of the crimped organic fibers for formingthe crimped pile fibers is more than 30%, in the resultant cut pilelayer, particularly after a heat-treatment is applied to the cut pilelayer, the crimped pile fibers (2) may exhibit an insufficient low pileheight, and a balance in the pile height of the crimped pile fibers (2)with the non-crimped pile fibers (1) and the crimped or non-crimped pilefibers (3) may become inadequate, and thus a target multi-coloredpattern of the cut pile layer may not be obtained. Also, in this case,when an etching treatment is applied locally to the resultant cut pilelayer, a target concave-and convex-pattern may not be obtained on theetched pile layer.

As mentioned above, it is important that the percentage crimp of thecrimped organic fibers for forming the crimped pile fibers (2) isestablished in response to processing conditions applied for theproduction of the desired pile fabric and, for example, toheat-treatment conditions applied to the cut pile layer formed through acut pile layer-forming procedure, so that the pile height of the crimpedpile fibers (2) comes into desired a level between the pile height ofthe non-crimped pile fibers (1) and that of the crimped or non-crimpedpile fibers (3).

In the case where the crimped pile-fibers (2) are formed fromfalse-twisted polyester filaments, a false-twisting procedure is appliedto a the polyester filament yarn, while appropriately adjusting thefalse twisting conditions such as false twist factor and false twistingtemperature to such an extent that the desired percentage crimp isattained.

The crimped or non-crimped organic fibers for forming the crimped ornon-crimped pile fibers (3) are preferably selected from those having ashrinkage in boiling water (BWS) of 40 to 80%, and enabling theresultant pile fibers (3) obtained after the cut pile layer-forming andfinishing procedures are applied to exhibit a desired pile height. Inthe case where polyester filaments are used as the organic fibers forforming the crimped or non-crimped pile fibers (3), such polyesterfilaments can be easily produced by the following procedures. Namely, acopolymerized polyester resin is prepared by copolymerizing a usualdicarboxylic acid component and a usual alkyleneglycol componenttogether with a third component comprising at least one member selectedfrom dicarboxylic acid components, for example, isophthalic acid,naphthalene dicarboxylic acids, adipic acid and sebacic acid; glycolcompounds, for example, diethyleneglycol and polyethyleneglycol; andbis-phenol A and bis-phenolsulfone, and is subjected to afilament-forming procedure; the resultant undrawn filament yarn isdirectly wound up, without drawing, at a winding speed of 3500 m/minute;the wound undrawn filament yarn are unwound and slightly drawn at atemperature of 60 to 80° C. at a draw ratio of 1.3 to 1.5.

The organic fibers for forming each of the pile fibers (1), (2) and (3)are used, to produce yarns for files optionally during being furtherdrawn or after drawing, alone or in a mixture of two or three types offibers with each other, in response to the structure of the target pilefabric, while being drawn or after drawing; the resultant fiber yarnsare incorporated into the ground structure portion of the pile fabric byknitting or weaving procedure, to form a loop pile layer or at least onesurface of the ground structure portion; and the loop piles are cut toconvert them into cut piles.

For the mixing of the organic fibers, conventional doubling orparalleling method, interlace-mixing method using an interlace nozzle,double-twisting method, and electrostatically opening and mixing method.Among these fiber-mixing methods, the interlace-mixing method using theinterlace nozzle is most appropriate for the formation of the pileyarns.

To form a cut pile layer having a knit structure, a ground structure isformed by a knitting procedure, and a loop pile structure, for example,a Sinker pile, pole tricot pile or double Raschel pile structure, isformed on the ground structure and then the resultant loop piles arecut.

The pole tricot piles is formed by converting the pile knit portion ofthe tricot knit structure to loop piles by using a raising machine.

To form a cut pile layer with a weave structure, a warp pile weave or aweft pile weave is produced by a weaving procedure, and cutting theresultant loop piles, or a moquet weave is produced and the pile yarnsare cut at the center of each pile.

The pile fabric is optionally heat-treated. In the case where the cutpile layer includes polyester pile fibers, especially, the pile fibers(1), (2) and (3) are respectively constituted from non-crimped, low heatshrinkage polyester filaments, crimped polyester filaments and crimpedor non-crimped, high heat shrinkage polyester filaments, a heattreatment is applied to the cut pile layer, so that the heat set crimpedpolyester filament (2) piles provide a desired middle pile height, thecrimped or non-crimped high heat shrinkage polyester filament (3) pilesare shrunk and provide a desired lowest pile height, and the non-crimpedlow heat shrinkage polyester filament (1) piles are maintained at thedesired highest pile height.

When the heat treatment for the above-mentioned polyester filaments iscarried out in accordance with a wet heating method, the heat treatmenttemperature is preferably in the range of from 80 to 130° C., morepreferably 100 to 110° C. When the heat treatment is carried out inaccordance with a dry heating method, the heat treatment temperature ispreferably in the range of from 150 to 200° C., more preferably 160 to180° C. If the wet heat treatment temperature is less than 80° C. or thedry heat treatment temperature is less than 150° C., thecrimp-generation and the heat setting effect on the crimped polyesterfilaments (2) may be insufficient. Also, if the wet heat treatmenttemperature is more than 130° C. or the dry heat treatment temperatureis more than 200° C., the elastic modulus of crimps of the crimpedpolyester filaments (2) may decrease, and/or the resultant pile fabricmay, as a whole, excessively shrinks and exhibit a stiff hand.

The pile fabric, which has a cut pile layer and, optionally, has beenheat-treated, is subjected to a usual pre-treatment and then to a dyeingtreatment, to dye the pile fibers (1), (2) and (3) in a way such that atleast one type of pile fibles of the pile fibers (1), (2) and (3) aredyed in a color different in hue and/or lightness from others. In thecase where the pile fibers (1), (2) and (3) are respectively constitutedfrom the non-crimped, low heat shrinkage polyester filaments, crimped,cationic dye-dyeable polyester filaments and crimped or non-crimped,high heat shrinkage polyester filaments, the resultant pile fabric isdyed in a dyeing both containing a disperse dye and a cationic dye so asto simultaneously dye the polyester filament piles (1), (2) and (3), toobtain a multi-colored fiber cut pile layer as mentioned above.

Alternatively, the non-crimped, low heat shrinkage polyester filaments(1) and the crimped or non-crimped, high heat shrinkage polyesterfilaments (3) are respectively produced from coloring pigment-containingpolyester resins and the crimped polyester filaments (2) are producedfrom a cationic dye-dyeable polyester resin, the resultant pile fabricis subjected to a dyeing procedure using a cationic dye-containingdyeing both to selectively dye the crimped polyester filament piles (2)with the cationic dye, and to obtain a multi-colored fiber pile fabric.

The multi-colored pile fabric of the present invention has a cut pilelayer in which the non-crimped pile fibers (1) having a highest pileheight, the crimped pile fibers (2) having a middle pile height and thecrimped or non-crimped pile fibers (3) having a lowest pile height aredistributed in the way as shown in each of FIGS. 1 to 4. In the cut pilelayer, the crimped pile fibers (2) has a high bulkiness caused by thecrimps thereof and thus, when the crimped pile fibers (2) aredistributed in the cut pile layer as shown in FIGS. 1 to 4, and the cutpile layer is observed from above, at least the non-crimped pile fibers(1) and the crimped pile fibers (2) appearing between the pile fibers(2) can be seen and, thereby, or by a combination of these pile fibers(1) and (2) and the knitting or weaving structures of the pile yarns, asprinkled multi-colored pattern or a grandrelle multi-colored pattern isformed in the cut pile layer. Also, the crimped pile fibers (2)contribute to preventing the laying flat of the fiber piles, byutilizing the high crimping elasticity of the pile fibers (2).

An embodiment (1) of the concave-and convex-patterned multi-coloredfiber pile fabric of the present invention is formed from themulti-colored fiber pile fabric of the present invention. In thisembodiment (1), top portions of the non-crimped pile fibers (1) locatedin at least one partial region of the cut pile layer are removed by achemical etching procedure to such an extent that the remainingnon-crimped pile fibers (1-a) have a pile height controlled within therange of lower than that of the original non-crimped pile fibers (1) butnot lower than that of the crimped pile fibers (2), to thereby form aconcavity in a partial region and to increase the degree of exposure ofthe top portions of the crimped pile fibers (2) located in theconcavity.

For example, in the explanatory cross-sectional profile of themulti-colored fiber pile fabric as shown in FIG. 5, the piles 4A, fromwhich a cut pile layer 4 is formed, are each constituted from thenon-crimped pile fibers 5, the crimped pile fibers 6 and crimped ornon-crimped pile fibers 7 which three types of pile fibers are mixedwith each other, in the same manner as shown in FIG. 1. In FIG. 5, in apartial region 8 of the cut pile layer 4, the pile heights of thecrimped pile fibers 6 and the crimped or non-crimped pile fibers 7 inthe piles 4Aa located in the partial region 8 are respectively the sameas those in the pile 4A. However, top portions of the non-crimped pilefibers 5 are removed by a chemical etching procedure, and thus theresultant etched non-crimped pile fibers 5 a have a pile height aboutthe same as or higher than that of the crimped pile fibers 6. Thus, thepartial region 8 forms a concave in the cut pile layer 4. Also, in thecut piles 4Aa in the partial region 8, the etched non-crimping pilefibers Sara has a pile height lower than the non-etched non-crimped pilefibers 5, and thus the degree of shielding for the crimped pile fibers 6and the crimped or non-crimped pile fibers 7 by the etched non-crimpedpile fibers 5 a is lower than that by the non-etched non-crimped pilefibers 5 in the cut piles 4A. In other words, the degree of exposure ofthe pile fibers 6 and 7 in the cut piles 4Aa is higher than that in thecut piles 4A, and thus the color appearance of the cut piles 4Aa isdifferent from that of the cut piles 4A. Accordingly, the partial region8 becomes different not only in the formation of a concavity but also inthe color appearance (pattern) from the region surrounding the partialregion 8, and thus the cut pile layer 4 exhibits, as a whole, acombination of the concave-and convex-pattern with the color pattern.

Another embodiment (2) of the concave-and convex-patterned multi-coloredfiber pile fabric of the present invention is formed from themulti-colored fiber pile fabric of the present invention. Thisembodiment (2) is characterized in that in at least one partial regionof the cut pile layer, top portions of the non-crimped pile fibers (1)and top portions of the crimped pile fibers (2) are removed by achemical etching procedure to such an extent that the remainingnon-crimped pile fibers (1-a) and the remaining crimped pile fibers(2-a) have pile heights controlled within the range of lower than thatof the original non-crimped pile fibers (1) but not lower than that ofthe crimped or non-crimped pile fibers (3), to thereby increase thedegree of exposure of the top portions of the remaining crimped pilefibers (2-a) and the crimped or non-crimped pile fibers (3) located inthe partial region.

For example, in FIG. 6, a cross-sectional profile of another embodimentof the concave-and convex-patterned multi-colored fiber pile fabric isshown. In the pile fabric shown in FIG. 6, a concave 8 is formed byremoving top portions of the non-crimped pile fibers 5 and the crimpedpile fibers 6 located in a partial region 8 in the same cut pile layer 4as that shown in FIG. 1, by a chemical etching procedure so that thepile heights of the etched pile fibers become to about the same at thatof the crimped or non-crimped pile fibers 7, and thus the degrees ofexposure of the etched pile fibers 6 a and 7 in the cut pile 4Ab becomehigher than that of the pile fibers 6 and 7 in the cut piles 4 shown inFIG. 1, and the degree of exposure of the pile fibers 7 becomes higherthan that of the pile fibers 7 in the cut piles 4Aa shown in FIG. 5.Accordingly, in the pile layer shown in FIG. 6, the partial region 8exhibit, together with the portions of the pile layers surrounding thepartial region 8, a concave-and convex-pattern, and the color pattern ofthe cut pile 4Ab in the partial region 8 is different from that of thecut piles 4A shown in FIG. 1 and the cut piles 4Aa shown in FIG. 5.

In the pile fabric shown in each of FIGS. 2 and 3, a pile fabric havinga composite pattern formed from a concave-and convex-pattern and a colorpattern can be obtained by removing top portions of the non-crimped pilefibers 7 in the cut pile fibers 4B and 4D located in the partial regionby a chemical etching procedure, to such an extent that the remainingpile fibers exhibit a pile height approximately the same as or slightlyhigher than the pile height of the crimped pile fibers 6; or by removingtop portions of the non-crimped pile fibers 5 and the crimped pilefibers 6 in the cut piles 4B, 4C and 4D by a chemical etching procedure,to such an extent that the remaining pile fibers exhibit a pile heightapproximately the same as or slightly higher than that of the crimped ornon-crimped pile fibers 7.

In the pile fabric shown in FIG. 7, a concavity is formed in a partialregion 8 of the pile fabric having the same constitution as that of thepile fabric shown in FIG. 4. In the concave region 8, a chemical etchingprocedure is applied to top portions of the non-crimped pile fibers 5and the crimped pile fibers 6 to remove the top portions to such anextent that the pile heights of the etched non-crimped pile fibers 5 andthe etched crimped pile fibers 6 become approximately the same as orslightly higher than that of the crimped or non-crimped pile fibers 7,to form cut piles 4Ea formed from the etched non-crimped pile fibers 5 band cut piles 4Fa formed from the etched crimped pile fibers 6 a, andthereby to provide with a color pattern formed from the above-mentionedcut piles 4Ea and 4Fa and cut piles 4G formed from the crimped ornon-crimped pile fibers 7. In this color pattern, the etched pile fibers5 and 6 having a decreased pile height causes the degrees of exposure ofthe cut piles 4Ta and 4G to increase. Therefore, the color pattern ofthe concave region 8 shown in FIG. 7 is different from the color patternof the pile fabric shown in FIG. 4, namely of the portions of the pilefabric surrounding the concave region 8. Accordingly, the formation ofthe concave region 8 enables a complicated pattern to be formed from acombination of the concave- and convex-pattern with the color pattern.

There is no limitation to the structure of the fabric material for thecut pile fabric of the present invention, and the structure may beappropriately established. As a fabric material for the cut pile fabricof the present invention, a loop pile fabric can be produced as follows.Namely, a knitted or woven fabric having a desired knitting or weavingstructure is produced from multi-filament yarns or spun yarns for aground structure portion and at least one type of filament yarns forforming piles having a desired fiber structure, in the resultant looppile fabric is subjected to a loop pile-cutting procedure, to provide acut pile fabric and then the resultant cut pile fabric is subjected toappropriate processing procedures to thereby form pile fibers (1), (2)and (3) each having a desired pile height.

To produce a pile knitted fabric having three types piles (1), (2) and(3) different in composition of the pile fibers from each other, as amaterial fabric, a loop pile knitted fabric is produced from, forexample, yarns 11 for forming a ground structure portion, filament yarnsFY(1) for forming piles (1) (for example, piles consisting ofnon-crimped pile fibers (1) only), filament yarns FY(2) for formingpiles (2) (for example, piles consisting of crimped pile fibers (2)only) and filament yarns FY(3) for forming piles (3) (for example, pilesconsisting of crimped or non-crimped pile fibers (3) only), inaccordance with the knitting structure as shown, for example, in FIG. 8.

To form the concave-and convex-pattern in the pile fabric of the presentinvention, a chemical etching procedure is applied by bringing achemical etching agent into contact with top portions of the non-crimpedpile fibers (1) or the non-crimped pile fibers (1) and the crimped pilefibers (2) located in partial regions of the cut pile layercorresponding to a predetermined pattern. For example, in the case wherethe pile fibers are polyester fibers or polyamide fibers, the chemicaletching procedure is carried out by bringing an aqueous sodium hydroxidesolution having a concentration of 25 to 40% by mass into contact withthe pile fibers of the pile fabric and then heating the pile fabric withsteam.

EXAMPLE

The present invention will be further illustrated by the followingexamples which are not intended to restrict the scope of the presentinvention in any way.

The products and the material yarns of the examples and comparativeexamples were subjected to the following tests and evaluations in theterms and by the measurement methods shown below.

(1) Shrinkage in Boiling Water (BWS)

A sample of a filament yarn to be tested was wound 10 times around asizing reel having a periphery length of 1.125 m, to provide a hank. Thehank was hung from a hanging hook on a scale board, a load correspondingto 1/30 of the total mass of the hank was applied to the lower end ofthe suspending hank, and a length L1 of the hank before shrinkingtreatment was measured.

The applied load was removed from the hank, the hank was placed in acotton bag, the bag containing the hank was immersed in boiling waterfor 30 minutes to allow the hank to freely shrink. The bag was removedfrom boiling water, the hank was taken out from the bag, water aroundthe hank yarn was removed by absorbing with filter paper sheets, and thehank was dried at room temperature for 24 hours. The dried hank was hungfrom the hook on the scale board, a load corresponding to 1/30 of thetotal mass of the hank was applied to the lower end of the suspendinghank, in the same manner as mentioned above, and the length L2 of thehank after the shrinking treatment was measured.

The shrinkage of the tested filament yarn in boiling water (BWS) wascalculated in accordance with the following equation.BWS(%)=[(L1−L2)/L1]×100(2) Percentage Crimp

A hank of the filament yarn to be tested having a dry thickness of 2333dtex was prepared by winding the filament yarn around a sizing reelhaving a periphery length of 1.125 m.

The hank was hung from a hook on a scale board, an initial load of 6 gwas applied to the lower end of the suspending hank, then an additionalload of 600 g was applied to the lower end of the hank and the length L0of the hank under load was measured. Immediately after the measurement,the loads were removed from the hank, and the hank was taken off thehook of the scale board, and was immersed in boiling water for 30minutes to allow the hank to freely shrink. The boiling water-treatedhank was taken out from boiling water, water around the hank yarn wasremoved by absorbing with filter paper sheets, then the hank was driedat room temperature for 24 hours.

The dried hank was hung from the hook on the scale board, a load of 600g was applied to the lower end of the suspending hank, one minute afterthe hanging, the length L1 a of the hank was measured, the load wasremoved from the hank, one minute after the removal of the load, thelength L2 a of the hank was measured.

The percentage crimp (CP) of the filament yarn was calculated inaccordance with the following equation.CP(%)=[(L1a−L2a)/L0]×100(3) Lightness

The lightness of a pile fabric was measured in accordance with theMunsell color system (JIS Z 8721).

(4) Resistance of Piles to Laying Flat

A weight in a cylindrical form having a diameter of 4 cm and a mass of500 g was placed on a center portion of a specimen (dimensions: 10 cm×10cm) of a pile fabric, and the weighted pile fabric was stored in aconstant temperature container at a temperature of 80° C. for 2 hours.Thereafter, the weight was removed from the pile fabric and then thefabric was left standing under no stretch condition at room temperaturefor 30 minutes.

Thereafter, a difference in pile-laying flat condition between theportion of the pile fabric on which the weight was placed and anotherportion of the file fabric surrounding the weight-placed portion wasobserved with the naked eye and evaluated into the following fiveclasses.

Class Pile-laying flat condition 5 No pile-laying flat is found. Usablein practice 4 Slight pile-laying flat is found. Usable in practice 3Moderate pile-laying flat is found. 2 Rather significant pile-layingflat is found. 1 Pile-laying flat is completed.(5) Evaluation of Multi-colored, Concave-and Convex-pattern of PileFabric

The multi-colored, concave-and convex-pattern appearing in the pilefabric was evaluated by the naked eye into the following three classes.

Class Multi-colored, concave-and convex-pattern 3 Good 2 Practicallyusable 1 Bad

Example 1

A polyethylene terephthalate multifilament yarn (yarn count: 84 dtex/36filaments) was heat-treated under treating conditions, namely a heaterlength of 2 m, a heat treatment temperature of 200° C., a heat-treatmentspeed of 500 m/min. and a overfeed percentage of 5%.

The resultant non-crimped polyester filament yarn (1) exhibited ashrinkage in boiling water of 1.2%.

Separately, a cationic dye-dyeable polyester was produced in such amanner that, in the production of polyethylene terephthalate by apolycondensation procedure, the acid component contained sodiumsulfoisophthalic acid in an amount of 2.6 molar %, based on the totalmolar amount of the acid component, to copolymerize the cationiccompound into the polyethylene terephthalate. From the resultantcationic dye-dyeable polyester, a crimped polyester filament yarn (2)having a yarn count of 100 dtex/24 filaments, and a crimp percentage of21% realized by a false-twisting procedure, was produced.

Further separately, a copolymerized polyester having a relativeviscosity of 1.45 was produced from an acid component comprisingterephthalic acid and isophthalic acid in a molar ratio of 93/7 and aglycol component comprising ethyleneglycol. The resultant copolyesterresin was subjected to a melt-spinning procedure and the resultantfilaments were wound-up at a winding-up speed of 3500 m/min., to producea partially oriented, undrawn copolyester multifilament yarn. Theundrawn multifilament yarn was drawn at a draw ratio of 1.4, withoutheat-setting, between a first roller having a temperature of 15° C. anda second roller having a temperature of 75° C. of a drawing apparatus,to produce a non-crimped copolyester filament yarn (yarn count: 100dtex/12 filaments). The resultant non-crimped copolyester filament yarnexhibited a shrinkage in boiling water (BWS) of 65%.

One of the non-crimped polyester filament yarns (1), one of the crimpedcationic dye-dyeable polyester filament yarns (2) and one of thenon-crimped copolyester filament yarns (3) are made parallel to eachother, the resultant parallel yarn was fed into a interlacing nozzle ofan interlace apparatus and the individual filaments in the parallel yarnwere mixed at an overfeed rate of 3%, at a yarn speed of 400 m/min. Theresultant filament mixed yarn consisting of three different types offilaments was used as a pile-forming yarn of a pile fabric. Also,non-crimped polyethylene terephthalate filament yarns having a yarncount of 167 dtex/48 filaments were used as a yarn for forming a groundstructure portion of the pile fabric.

The above mentioned filament yarns were fed to all the reeds of awarp-knitting machine (made by KARL MAYER CO.) provided with 28 gaugeball sinker, to produce a loop pile fabric having the followingstructures

Ground structure:

-   -   Courses: 23.6 yarns/cm    -   Wales: 11.1 yarns/cm

Pile structure: Loop pile length: 2.5 mm

The resultant loop pile fabric was subjected to a shearing procedureusing a shearing machine (made by Nikki K.K.) to cut the pop portion ofthe loop piles at 0.2 mm, and to convert the loop piles to cut piles.The resultant cut pile fabric was subjected in an opened form to a dryheat-setting procedure using a dry heat-setter at a temperature of 180°C. for 45 seconds, to stabilize in dimension the non-crimped polyesterfilaments (1), to fully complete the crimping of the cationicdye-dyeable polyester filaments (2) and to fully heat shrink thenon-crimped copolyester filaments (3). The resultant cut pile fabric hada basis mass of 100 g/m².

The cut pile fabric was subjected to a dyeing procedure using a dyeingboth containing the dye composition shown below.

Teratop Pink 2GLA (trademark, 1.8% (based on the made by Ciba-Gaygy)fabric mass) Teratop Blue HLB (trademark, 0.4% (based on the made byCiba-Geigy) fabric mass) Bismarck Brown B (trademark, 3.5% (based on themade by NIHON KAGAKU K.K.) fabric mass) Irgasol DAM (trademark, made by1 g/liter Ciba-Geigy) Acetic acid 0.5 g/liter

The dyeing procedure was carried out in a liquid stream dyeing machine(made by HISAKA SEISAKUSHO), at a temperature of 130° C. for 45 minutes.

By the above-mentioned dyeing procedure, the crimped cationicdye-dyeable polyester filaments (2) were dyed in a brown color (at alightness of 50), the non-crimped copolyester filaments (3) were dyed ina purplish red color (at a lightness of 43) and the non-crimpedpolyester filaments were dyed in a light purplish pink color (at alightness of 65).

The dyed cut pile fabric was dried by using a short loop dryer (made byHIRANO TEXEED K.K.) at a temperature of 120° C. for 2 minutes. The driedcut pile fabric was subjected to a heat treatment using a dry heatsetter (made by HIRANO TEXEED) at a temperature of 160° C. for oneminute, while removing winkles from the fabric

In each cut pile in the resultant cut pile fabric, non-crimped pilefibers (1) having a highest pile height were formed from the non-crimpedpolyester filaments (1), crimped pile fibers (2) having a middle pileheight were formed from the cationic dye-dyeable polyester filaments (2)and non-crimped pile fibers (3) having lowest pile height were formedfrom the non-crimped copolyester filaments (3).

Then, a concave-and convex-pattern-forming treatment was applied to thecut pile layer of the above-mentioned cut pile fabric, by the followingprocedures.

A printing screen frame A was prepared by forming dye paste-permeatingportions in a pattern of light blue spots in a mesh fabric #700 having apermeability of 30%, for screen printing. Separately, a printing screenframe B was prepared by forming dye paste-permeating portions in apattern of light blue spots, which patterns are superposed on thepattern in the frame (A), in a mesh fabric #700 having a permeability of80% for screen printing.

An alkali paste for etching was prepared by dissolving an aqueous sodiumhydroxide solution having a concentration of 269.4 g/litter (Baumédegree of 28) and a size for etching agent (trademark; Cebtex T-36, madeby SHOEI RIKEN K.K.) in water at room temperature to provide an alkalisize for etching having a solid concentration of 35.5% by mass and aviscosity of 4 Pa·s (4000 cP). The alkali size for etching was printedin the pattern of light blue spots on the cut pile layer surface of thecut pile fabric, through the printing screen frames A and B with theprinting pattern of light blue spots. The printed alkali size was driedat a temperature of 140° C. for 10 minutes, and steam-treated withsaturated steam at a temperature of 170° C. for 15 minutes. On the cutpile layer, in the printed portions in the light blue spot patternthrough the printing screen frame A (namely in the first light blue spotpattern-printed portions), top portions of the non-crimped polyesterpile fibers (1) are removed to such an extend the remaining (non-topremoved) pile fibers (1) had a pile height equal to that of the crimpedcationic dye-dyeable polyester pile fibers (2), and in the printedportions in the light blue spot pattern through the printing screenframe B (namely, in the second light blue spot pattern-printedportions), top portions of the non-crimped polyester pile fibers (1) andthe crimped cationic dye-dyeable polyester pile fibers were removed tosuch an extent that the remaining (non-top removed) pile fibers (1) and(2) have a pile height equal to that of the non-crimped copolyester pilefibers (3). Namely, the first light blue spot-patterned portions in thecut pile layer form small depth concavities and in the portions, the topportions of the non-crimped pile fibers (1) and the crimped pile fibers(2) are exposed outside. Also, the second light blue spot-patternedportions in the cut pile layer form large depth concavities and in theportions, all the three colors of the non-crimped pile fibers (1),crimped pile fibers (2) and non-crimped pile fibers (3) are exposed. Inother portions of the cut pile layer surrounding the first and secondlight blue-patterned portions, the crimped pile fibers (2) are shieldedby the non-crimped pile fibers (1) and the non-crimped pile fibers (3)are shielded by the non-crimped pile fibers (1) and the crimped pilefibers (2), and thus in the appearance of the cut pile layer observedfrom above, portions of the crimped pile fibers (2) are seen in asprinkled color pattern (a pepper-in-salt-like color pattern) through amatrix consisting of the non-crimped pile fibers (1), and thenon-crimped pile fibers (3) are slightly and sprinkly seen throughnon-crimped pile fibers (1) and (2). Accordingly, in the resultant pilefabric with the concave-and convex-pattern; a concave-and convex-patternformed from the small depth concave portions, the large depth concaveportions and the portions surrounding the concave portions, is combinedwith a color pattern formed from the small depth concavity portions, thelarge depth concave portions and portions surrounding the concaveportions, which are different in the degree of exposure to the threetypes of pile fibers different in hue and/or lightness from each otherand located in the above-mentioned portions.

The test results are shown in Table 1.

Example 2

A concave-and convex-patterned multi-colored fiber pile fabric wasproduced by the same procedures as in Example 1 with the followingexceptions.

As filament yarns for forming the non-crimped pile fibers (1),non-crimped polyester (polyethylene terephthalate) filaments (1) formedfrom a resin colored with a black-coloring pigment and having a yarncount of. 75 dtex/36 yarns were employed. The filaments (1) exhibited ashrinkage in water of 1.2%.

Also, in the dyeing procedure, the dyeing both contained no Teratop Pink2GLA and no Teratop Blue HLB. Thus, in the cut pile layer, the crimpedcationic dye-dyeable polyester filaments (2) were dyed in a brown colorand the dyed color was different in hue and lightness from the blackcolor of the non-crimped polyester filaments (1). Further, thenon-crimped copolyester filaments (3) were not colored by the dyeingprocedure.

In the chemically etched cut pile fabric, a concave-and convex-patternwas formed from large depth concavities and small depth concavities. Theappearance of portions of the pile layer surrounding the concaveportions is formed from the non-crimped pile fibers (2) colored in ablack color with-the black coloring pigment and having a highest pileheight, the brown-colored crimped pile fibers (2) partially seen throughthe crimped pile fibers (1) shielding the pile fibers (2) and thenon-colored non-crimped pile fibers slightly seen in a-sprinkled colorpattern (a pepper-in-salt-like color pattern) through the pile fibers(1) and (2) shielding the pile fibers (3). In the appearance of thesmall depth concave portions of the pile layer, the degrees of exposureof the brown-colored crimped pile fibers (2) and the non-colorednon-crimped pile fibers was higher than that in the-surroundingportions. In the appearance of the large depth concave portion of thepile layer, the degrees of exposure-of the pile fibers (2) and (3) werefurther increased. Thus, the appearances of the concave-surroundingportions, the small depth concave portions and the large depth concaveportions were different in color pattern from each other.

The test results are shown in Table 1.

Example 3

A concave-and convex-patterned multi-colored fiber pile fabric wasproduced by the same manner as in Example 1, with the followingexceptions.

Three types of pile-forming filament yarns (1), (2) and (3) each havinga total thickness of 284 dtex were respectively prepared from thepolyester (PET) filaments (1) for the non-crimped pile fibers (1), thecationic dye-dyeable polyester filaments (2) for the crimped pile fibers(2) and non-crimped copolyester filaments (3) for the non-crimped pilefibers (3).

The filament yarns (1), (2) and (3) for forming the pile layer and thesame polyester filament yarn as in Example 1 for forming the groundstructure portion were subjected to a knitting procedure in the knittingstructure shown in FIG. 8, to produce a pile fabric. In the resultantpile fabric, a combination of a light purplish red-colored pile ridgeconsisting of non-crimped polyester pile fibers (1) and having a highestpile height and a high lightness; a brown-colored pile ridge consistingof the crimped cationic dye-dyeable polyester pile fibers (2) and havinga middle pile height; and a purplish red-colored pile ridge consistingof the non-crimped copolyester pile fibers (3) having a lowest pileheight and a moderate lightness, each ridge extending in the coursedirection of the pile fabric, were repeatedly arranged in the waledirections.

The cut pile layer was subjected to the same chemical etching procedurewith alkali as in Example 1, to form the small depth concave portionsand the large depth concave portions in the light blue spot pattern. Theconcavity-surrounding portions of the resultant cut pile layer have acombination of the light purplish red-colored cut pile ridges of thepile fibers (1), the brown-colored cut pile ridges of the pile fibers(2), and the pile ridges of the pile fibers (3) having a darkerpurplished red color than that of the pile fibers (1), and the pileridges formed from the pile fibers (1) and having a highest pile heightpartially shield the pile ridges formed from each of the pile fibers (2)and (3) and having a lower pile height than that of the pile fibers (1).

Also, in the small depth concave portions, the degree of exposure of thepile ridges formed from the pile fibers (2) (brown-colored) was higherthan that in the concavity-surrounding portions. In the large depthconcave portions, the degree of exposure of the pile fibers (3) (coloredin a relatively dark purplish red color) was higher than that in thesmall depth concave portions.

The test results are shown in Table 1.

Example 4

A concave-and convex-patterned multi-colored fiber pile fabric wasproduced by the same manner as in Example 1, with the followingexceptions.

The crimped cationic dye-dyeable polyester filament yarns used as thecrimped pile fiber (2)-forming filaments (2) were replaced by crimpednylon 66 filament yarns (having a yarn count of 78 dtex/34 filaments,and a percentage crimp of 15%).

Also, in the dyeing both, Bismarck Brown B was replaced by Sumitomo FastYellow EGG (trademark, made by SUMITOMO KAGAKUKOGYO K.K.) in an amountof 3% by mass based on the mass of the yarn), and the dyeing bothtemperature was changed to 120° C. The crimped nylon filaments (2) weredyed in yellow color.

The test results are shown in Table 1.

Comparative Example 1

A concave-and convex-patterned multi-colored fiber pile fabric wasproduced by the same manner as in Example 1, with the followingexceptions.

The crimped cationic dye-dyeable polyester filament yarns for formingthe crimped pile fibers (2) were replaced by non-crimped filament yarnscomprising the same cationic dye-dyeable polyester as used in Example 1,having a shrinkage in boiling water of 5% and a yarn count of 100dtex/24 filaments. In the resultant cut pile fabric before applying theetching procedure, the pile fibers (1) and the comparative pile fiberswere both formed from non-crimped filament yarns and have approximatelythe same pile height from each other, and therefore exhibitedinsufficient bulkiness. Also, the resultant multi-color pattern of thecut pile layer was unsatisfactory. Further, after the small depthconcave portions and the large depth concave portions were formed by thealkali-etching treatment, the absence of the crimped pile fibers causedthe resultant concave-and convex-pattern and the color pattern were bothunsatisfactory. Also, the resultant cut pile layer exhibited aninsufficient resistance, of the file fibers, to laying flat.

The test results are shown in Table 1.

Comparative Example 2

A concave-and convex-patterned multi-colored fiber pile fabric wasproduced by the same manner as in Example 1, with the followingexceptions.

The cationic dye-dyeable polyester filament yarns for the crimped pilefibers (2) were replaced by crimped filament yarns having a shrinkage of20% and comprising the same polyester (PET) resin as that of thepolyester filament yarns for the non-crimped pile fibers (1).

The resultant pile fabric exhibited a high resistance of the pile fibersto laying flat. However, as the pile fibers (1) and the pile fibers (2)exhibited the same hue and the same lightness as each other, theresultant multi-color pattern was unsatisfactory.

TABLE 1 Example No Comparative Example Example Item 1 2 3 4 1 2Shrinkage (%) in 1.2 1.2 1.2 1.2 1.2 1.2 boiling water of filaments fornon- crimped pile fibers (1) Percentage crimp (%) 21 21 21 15 None 20 offilaments of crimped pile fibers (2) Shrinkage (%) in 65 65 65 65 65 65boiling water of filaments for crimped or non- crimped pile fibers (3)Hue and None- Light Black Light Light Light Light lightness crimpedpurplish purplish purplish purplish purplish pile red red red red redfibers (1) 65 12 65 65 65 69 Crimped Brown Brown Brown Yellow BrownLight pile purplish fibers (2) red 50 50 50 73 50 67 Crimped or PurplishWhite Purplish Purplish Purplish Purplish non- red red red red redcrimped pile fibers (3) 43 88 43 43 43 50 Resistance of pile 4 4 4 4 2 4fibers in cut pile layer (class) Appearance of cut 4 4 4 3 2 1 pilelayer (class)

Industrial Applicability

The multi-colored fiber pile fabric of the present invention exhibits anexcellent resistance of pile fibers to laying flat and a preferablemulti-colored pattern and thus has a high industrial applicability.

Also, the concave-and convex-patterned multi-colored fiber pile fabricof the present invention has an excellent resistance of the pile fibersto laying flat and a pleasant combination of the multicolor pattern andthe concave-and convex-pattern and exhibit a high practicalutilizability.

1. A concave-and convex-patterned multi-colored fiber pile fabricproduced from the multi-colored fiber pile fabric comprising a groundstructure portion having a knit or weave structure formed from organicfiber yarns and at least one cut pile layer comprising a plurality ofcut piles, combined with the ground structure portion by a knitting orweaving procedure of the organic fiber yarns, and extending outward fromat least one surface side of the ground structure portion, the cut pilelayer comprises (1) non-crimped pile fibers comprising non-crimpedorganic fibers, (2) crimped pile fibers comprising crimped organicfibers and having a pile height lower than that of the non-crimped pilefibers (1), and (3) crimped or non-crimped pile fibers comprisingcrimped or non-crimped organic fibers and having a pile height lowerthan that of the crimped pile fibers (2), and at least one type of pilefibers of the pile fibers (1), (2) and (3) having a color different inlightness or hue or in lightness and hue from the other or others,wherein in at least one partial region of the cut pile layer, topportions of the non-crimped pile fibers (1) are removed by a chemicaletching procedure to such an extent that the remaining non-crimped pilefibers (1-a) have a pile height controlled within the range of lowerthan that of the original non-crimped pile fibers (1) but not lower thanthat of the crimped pile fibers (2), to thereby increase the degree ofexposure of the top portions of the crimped pile fibers (2) located inthe partial region.
 2. The concave and convex-patterned multi-coloredpile fabric as claimed in claim 1, wherein the cut pile layer comprisesmixed fiber cut piles, in each of which piles, three types of the pilefibers of the non-crimped pile fibers ( ), the crimped pile fibers (2)and crimped or non-crimped pile fibers (3) are mixed altogether.
 3. Theconcave and convex-patterned multi-colored pile fabric as claimed inclaim 1, wherein the cut pile layer comprises mixed fiber cut piles, ineach of which piles, at least two types of pile fibers of thenon-crimped pile fibers (1), the crimped pile fibers (2) and the crimpedor non-crimped pile fibers (3) are mixed with each other.
 4. The concaveand convex-patterned multi-colored pile fabric as claimed in claim 1,wherein the cut pile layer comprises a plurality of non-crimped cutpiles consisting of only the non-crimped pile fibers (1), a plurality ofcrimped cut piles consisting of only the crimped pile fibers (2) and aplurality of crimped or non-crimped cut piles consisting of only thecrimped or non-crimped pile fibers (3).
 5. The concave andconvex-patterned multi-colored pile fabric as claimed in claim 1,wherein the non-crimped pile fibers (1) are selected from the groupconsisting of non-crimped polyethylene terephthalate fibers, non-crimpedpolybutylene terephthalate fibers, non-crimped polytetramethyleneterephthalate fibers, and non-crimped polytrimethylene terephthalatefibers.
 6. The concave and convex-patterned multi-colored pile fabric asclaimed in claim 1, wherein the crimped pile fibers (2) are selectedfront cationic dye-dyeable crimped polyester fibers.
 7. The concave andconvex-patterned multi-colored pile fabric as claimed in claim 1,wherein the crimped or non-crimped pile fibers (3) comprise a polyestercopolymer, the principal monomers or the copolymer are ethylene glycoland terephthalic acid, the comonomer copolymerized with the principalmonomers is at least one member selected from isophthalic acid,naphthalene dicarboxylic acid, adipic acid, and sebacic acid,diethyleneglycol, polyethyleneglycols, bis-phenol and bis-phenol sulfon.8. The concave and convex-patterned multi-colored pile fabric as claimedin claim 1, wherein either one type of pile fibers or the non-crimpedpile fibers (1) and the crimped or non-crimped pile fibers (3) arecolored with a pigment mixed in to a polymer component from which thepile fibers are formed.
 9. The concave and convex patternedmulti-colored fiber pile of fabric as claimed in any one of claims 1 and2 to 8, wherein in at least one partial region of the cut pile layer,top portions of the non-crimped pile fibers (1) and the crimped pilefibers (2) are further removed, together with the top portions of thenon-crimped pile fibers (1), by a chemical etching procedure to such anextent that the remaining non-crimped pile fibers (1-a) and theremaining crimped pile fibers (2-a) have pile heights controlled withinthe range of lower than that of the original crimped pile fibers (2) butnot lower than that of the crimped or non-crimped pile fibers (3), tothereby increase the degree of exposure of the top portions of theremaining crimped pile fibers (2-a) and the crimped or non-crimped pilefibers (3) located in the partial region.